Jeep Cherokee: ZJ Fuel Tank Upgrade [‘97-’01 XJ] (23 Gallon gas tank)

How to put a 1997-1998 Jeep Grand Cherokee (ZJ) Fuel Tank into a 1997-2001 Jeep Cherokee (XJ) to increase the total fuel capacity from 20.2 Gallons to 23.0 Gallons.
Link to Original Forum: www.naxja.org/forum/showthrea...
At the end of everything, this ended up costing about $300: that may seem like a stupid amount (and it is) but that includes
all Products used:
-1997 ZJ Fuel Tank
-2001 XJ Fuel Pump Assembly www.rockauto.com/en/catalog/j...
-2001 XJ Fuel Tank Seal www.rockauto.com/en/moreinfo....
-2001 XJ Fuel Tank Straps www.rockauto.com/en/catalog/j...
-2001 XJ Fuel Tank Filler Hoses www.ebay.com/itm/153930118414...
-2’ of ¼” Fuel Rated hose and a ¼” to 5/16” Adaptor fitting
-Rust stop, Reformer, and Undercoating
All the tools:
-9/16 Ratchet wrench
-Jack and Wood
-7mm Mini ratchet (Extension), Hose Clamp Socket
-Punch or Screwdriver
-Mallet, Pliers (maybe)
-Vacuum or Compressed air
-Cleaning supplies
-Gas Can
-FIRE EXTINGUISHER
This was way harder than it should have been, and I’m mad about it.
Fuel Range Confirmation: [Awaiting Data]
In short, the ZJ tank literally just bolts into place. There's nothing to it. I'm surprised more people didn't know about this swap!
00:00 Video Start
00:04 What's Happening
03:49 What You Need
05:32 Tank Removal
12:15 Fuel Pump Removal
14:53 Clean the Gas Tank!
15:47 Fuel Pump Installation
22:00 Rant Over
22:36 Tank Installation
26:19 Don't forget to add gas
The House: • Video
Next up - Operation MJ Part 11: • Jeep Comanche - 4wd Sy...
I do plan on making a follow up video with some results comparing the new range with the ZJ tank. Most recently, I traveled 345 miles before the low fuel light came on, which is farther than I could've gone with the XJ tank entirely. That was averaging 16.7 MPG, and I usually achieve 20+ MPG so assuming you hold a steady 20 MPG you'll have a range of 410 miles- BEFORE the low fuel light will come on. That's epic.

[@mrkultra1655]

Ok man, first off, wicked mod. This may be the first thing I do to the 2001 XJ that I just picked up. It came out of Atlanta, only been here in Western MA for about two years, and babied, and cleaned, and garaged the whole time it’s been here, so it’s f#@%ing immaculate (sorry to make anybody jealous). One word of advice, though. I’ve been wrenching and hot-rodding for a LONG time. Whenever you’re working on anything fuel injected, pull the fuse for the fuel pump, start the vehicle, and let it stall. Then crank it a bit more to make sure that it won’t start. Only then is it ok to open up the fuel system for any kind part replacement or whatever. You get WAY much less fuel spillage, if any, when you start disconnecting lines, fittings etc... You sir, have earned another subscription. 👍🏻

[@Vickyvee97]

Great tutorial btw, but one thing some of us have 15 gallon tanks (99 xj sport) and this is leaps and bounds improvement over what was offered as stock!!

[@gzrgldr8288]

Your rant was most appreciated. Having experienced the same issues with the fuel pump prior to watching your video, I can relate to all of the "how-to" videos out there that in no way capture the frustration that goes with it. I'm sure your video and explanation will be welcomed by newcomers to this repair.

[@WAEMIDIV]

That's what I try to do, and it's a challenge to balance that line - if I complain too much, people get disinterested. If not enough, people get mad because everything goes too well and they can't relate. I should've been more "professional" about it, but I was also just genuinely pissed off and didn't care anymore, yanno live and learn

[@WAEMIDIV]

@@nathanmccumber8965 that sounds like it would require some modification, considering the Genright tank is 30 gallons and *barely* fits between the axle, leaf springs, exhaust, floor, and bumper, I don't see how an additional 12 gallons on top of that would realistically fit in there. There's also the matter of fuel pump compatibility, sending unit compatibility, tank strap compatibility, and filler hose/ vent hose compatibility. I searched the internets for evidence of this alleged 42 gallon tank swap in an XJ, and only found 1 guy who claimed to have done it, who provided 0 details and also declared it was done on a Wagoneer, not an XJ. So uh... I think I need some more proof than "u can do et" make a video

[@DeathfireD]

That sound of relief when the bolt doesn't snap haha. I know that feeling.

[@WAEMIDIV]

ooooh yeah, I had to be real careful with that shield. Probably hasn't been touched since it was first assembled, but luckily I've got the magic touch when it comes to rusty bolts

[@99jeepxjguy97]

Caught that too . . ha ha

[@knucklerama]

Classic video!!! So true on Jeep projects and peoples lack of "truth"......everything fits perfectly in their install videos. If you've own as many Jeeps as I have, its rare that an after market part fits perfectly and "no modification is required". Keep up the great videos and commentary!

[@redtango75]

Update being on the reinstall step now. What brother WAEMIDV says is verified regarding the Delphi seal. I bought the Delphi pump regardless of the seal issues since Bosch was not obtainable. Other names out there I never heard of. Thanks to this video I had the OEM Mopar seal on hand. My technique was to put the seal 1/2 way in the tank. Getting the pump dead centered over the opening is key, as is lube, up down and all around. The other mofo part of this job was the old hose clamps. No amount of peanut butter was going to undo those rust nuggets. I'm not proud of it , but I used a dremel near an openly vented gas tank. Had water soaked rags covering everything, ate my vegetables, and prayed hard. Zip zip.

[@OverlandingJoy]

Great sense of humor. I'm saving this vid so when my fuel pump bites it..I'll have some guidance.

[@shiyouniaishiya]

Just found your channel and been loving your vids so far, keep up the good work!

[@alanwarner684]

Gas tanks are a royal pain!! Great job!

[@j.d.mcginn6946]

Wow great video you have saved a lot of time for others following you esp on the pump! I'm looking forward to doing this! Great idea on the zj swap. So much work on all the tanks you researched!

[@GhettoFabulous99]

DEFINITELY earned another sub here. Rant was based AF. Well done.

[@davidchristensen2970]

Excellent video 👍

[@richtyler1353]

Thank you this was very informative. It will be a great help when I swap mine

[@codysmith8256]

the epic neg battery disconnect moment got my like. I was already on board, but that was the moment I hit like. So, thanks for that.

[@propellantstudios706]

Great tutorial! Loved the honest commentary. If you really want to feel the pain of a lack of tutorial information online, buy a Subaru as your 2nd vehicle like me...

[@WAEMIDIV]

Yeap one of my friends has an 02 Outback and he procrastinates on everything because of this He keeps telling me to make videos on it but never lets me borrow it, nor does he ever buy parts, so I think you should yell at him and I might make some Subaru videos lol

[@axerxes3981]

Thanks for the video my friend. I'm noob and this helped me a lot with several things. It's nice to see other people struggle with problems too. Thanks!! Best wishes..... Ax

[@bradlfsh]

Yeah you make good videos man, hope you keep them coming 👍

[@treychastain4686]

Seeing how I bought a zj just for the motor, I'll now be pulling the tank out for my xj. Thank you for all the info

[@WAEMIDIV]

epic move!

[@andrewchristiansen8311]

Thank you so much for making this video as honestly as you did. I had this Idea and found your video instantly. I'm moving to Alaska and absolutely need the extra 3 gallons. Glad it does actually fit. I also found that 30.5 gallon tank. Its 1850$ now!!! I can get a performer head for that! Subscribed....

[@gundude82]

A lot of people have bought entire cherokees for less than that!

[@Gaston.-]

Good info. I appreciate the depth. And comedy

[@WAEMIDIV]

I have earned the respect of Gastón, I think I have peaked

[@ericsxj1975]

Nice video. I definitely would do this if/when I have to lower the stock tank.

[@gnazziog5226]

Good content liked and subbed. Gotta do one on a 98 xj. Perfect timing. Thank you

[@WAEMIDIV]

Perfect Timing yes! You're my 1,936th subscriber - Indiana Jones and the Raiders of the Lost Ark took place in 1936 The movie's runtime is 1 hour and 45 minutes 1+4+5 = 10 at the moment I'm typing this, the video has 10 views, you're probably the tenth ILLUMINATI CONFIRMED

[@dugdug007]

Agree with the rant completely

[@DustySteel]

Awesome video! My 3 hour projects turn into 21 days as well lol.

[@jacobwhittaker6241]

I hate that I can relate to this so much.

[@remmahneb]

Thanks for the rant! I totally agree.

[@05glisedan]

Thank you very much for posting this. I'll be using it on my removal. I think, I may create a access hatch in the rear floor pan. That, tank dropping business...sucks.

[@WAEMIDIV]

it ain't that bad, especially compared to modern cars. It's tight, uncomfortable and inconvenient, but at least you don't need to remove the entire rear axle and tear apart the back seat/ interior like some cars I think cutting a hole in the floor is unnecessary, because (if you're putting in a ZJ tank) you're gonna have to remove it anyway, and how often are you gonna replace the fuel pump? They last 150,000+ miles easily; and doing the job every 15 years (if you even still have the Jeep by then) doesn't seem like enough to warrant cutting a hole in the body. Just my opinion though

[@baltod4978]

I love this! Thank you!

[@HobbesVids]

I Don't have an XJ, i only have an MJ with a tank that's even better than the ZJ like you said in the video, and i still watched this whole thing cause I'm really liking your content! keep it up man! following in your adventures is fun!

[@WAEMIDIV]

Thank you! I do have an MJ Series as well, but it's not as refined what year is your truck?

[@HobbesVids]

@@WAEMIDIV it’s a 1988, same as yours i Think!

[@CalQwax]

Good stuff. I bought a ZJ tank and installed it into my 2000 XJ. I would bend the heat shield away from the tank and more toward the muffler. Thanks for the info and video. I have a video on how to drain the tank. Last low fuel light fill up it took 21.1 gallons.

[@paveldvorak915]

How do you drain the tank? Can i see the video? I got a full tank now need to remove it

[@softaildude98]

great vid i have same jeep same color same problem with evap lol now i know how to check it so thanks.

[@stevenloughran6715]

Are you a news caster ? Bro if you ain’t you should be ! 🤣 Instant fame. Great vid, jeep em comin !

[@WAEMIDIV]

I thought about doing news but that would require me to be well informed, which I am never

[@illustriousbrainqueef1823]

Excellent breakdown on the swap. I have to change the tank in my 96 but I’m probably just going to go with a stock tank. I have no idea which ZJ tank would fit a 96

[@citizenatlrge]

Bruh.. You've got another subscriber. Keep it going lol

[@WAEMIDIV]

Thanks bruh, am trying ✅

[@ZekeMaster85]

Mint rant

[@casper5478]

Just watched another video that led to this as I have a leak above the tank. I will be pulling it again. I had the same issues with the tank seal and also went to the dealer for it. Going to order another to have on hand before I drop it.

[@Deadbuck73]

This is a great video. All your videos are fantastic. Did you have one for the under hood light. My light is out. I’m afraid of breaking it off.

[@LouieGiNYC]

You: oh you thought we were done with that? Oh no..... Me: spit out my soda laughing.

[@broheim23]

I've watched a half dozen of your videos and I'd like to give you some feedback. 1. Your presentation of information is precise, concise and linear. Very well done! 2. Your jokes are good; lightly poking fun (mostly at your ex's expense), but not malicious. This is a hard line to walk and much appreciated. 3. Your humor is in line with This Old Tony. If you're not familiar with him, check out his YT channel. (He has more than a million subs so I can't really give you a higher compliment.) Now I have a question: specifically which RedHead box did you buy? The 18510 or the quick ratio 18510QW?

[@WAEMIDIV]

Well thanks man, I do really try to thoroughly research a project before making a video on it, as a way to try and answer people's questions before they even have them. Sometimes I do miss things though, I am trying to get better The ex jokes are a fine line to walk, you're right. I do need to chill out with it I think, but people seem to like them. She really broke me as a person, it was a devastating separation and 2 years later I finally feel at peace with things- I think that because we can all laugh in some sort of a related way; that people like the jokes, it's helped me move on. Crazy to think that youtube could help with such a thing. I haven't seen This Old Tony but I'll start watching immediately. For the steering box I got 18510, linked here: offroadpowerproducts.com/redhead-steering-gear-box-1980-2002-all-jeep-s-except-cj-s-15-1-ratio-3-mount-holes.html I very much appreciate the compliments, comments like these motivate me to keep going - very much needed especially come winter. Thank you

[@ekbanjosworld4926]

Ha ha! Love the EX jokes! I'm divorced from 2 different Succubus from HELL! I paid child support for 25 years and gave up 4 homes because of thier infidelity! Basically I stopped putting up with thier bullshit and they decided to move on while still married! What I appreciate most is your honesty! Working on these old Jeeps is a BITCH! Nothing ever seems to go smoothly and when it does, I keep waiting and watching for something else really stupid to happen ! No better feeling than sitting back when the job is done !

[@rsjohnson7436]

a light coat of silicone grease on the fuel pump gasket/o-ring goes a long way to getting it in without all that hassle and getting a proper seal.

[@prateekkumud1275]

Best part at 27:29 " well what do you know,WHATDOYOUKNOW" 😆

[@toxictiger_]

First off I'd like too thank you for your amazingly clear and human videos (this one really brought out the human) just got my first xj (98 lmtd) and all of them have been extremely helpful, now out of random curiosity how does the larger tank affect the fuel gauge on the dash, like does it go over full or does it stay at full for an extra 3 gallons TIA

[@WAEMIDIV]

It reads full for the first ~100 miles of driving. The needle just doesn't move until it burns maybe 4 gallons. Even still, it will read below Empty with about 2 gallons left, but there's no reason to run it that low anyway

[@jacobwhittaker6241]

Honestly if the fuel pump starts to go in our XJ I'll probably just keep driving it and pre-prepare a ZJ tank to go in it. I'll be downloading your video to keep it, hope you don't mind...... Lol

[@WAEMIDIV]

That's pretty much how I approached this "mod", not something to go out of your way doing but an upgrade nonetheless. Download all you want fam

[@99jeepxjguy97]

Hey ! This is awesome! The first question that came to mind is . .. Do you think the factory skid plate will still fit? I know you made mention of skid plates, but not whether you thought it would actually fit. The ZJ plates will fit the XJ though. Otherwise, great video. Well presented. Unlike a lot of others. Haha

[@WAEMIDIV]

I don't think the XJ skid plate will fit. Some forums mentioned needing to grab the ZJ Skid if you want one. It might fit, I don't know, I've never seen a Skid plate on a gas tank here in the rust belt

[@drgil65]

😆 Your right, it’s never as easy as they show on the videos 😆😆

[@lavapix]

60 more miles when living on an island is a big gain. I could also achieve $100 fill-ups.

[@redtango75]

Great job! So the 1/4" fuel rated line in the description, is that the evap line you ran from the tank to the charcoal canister?

[@WAEMIDIV]

yes, but the fitting for that same line on the charcoal canister is 5/8", so you'll need an adaptor fitting and some 5/8" hose as well. Normally that line is metal, and if you still have your metal line and it isn't rusted out, you just need the 1/4" hose

[@picflight]

Which seal was causing the Evap code? Did the tank swap cure the Evap code? Your tip on installing the pump and gasket is very valuable!!

[@WAEMIDIV]

I never found out exactly what it was, but the tank swap did in fact make the EVAP leak go away.

[@GF_Burke]

Nice man. Think my same gas tank XJ skid will still work fine? *nm. Just looked on that forum and dude said same part #.

[@austinthomas3689]

Awesome video didn’t know this was such a simple swap. What is the difference in clearance from the ground compared to the original xj tank?

[@WAEMIDIV]

Not sure on that, the ZJ tank does hang slightly lower though. It can't be more than about 1", but I know everything counts out on the trail I don't ever offroad mine so I didn't even think to look for the ground clearance. It should be the same departure angle as a ZJ I'd imagine

[@jeremyhanna3852]

This will also work on older cherokees you just need to make your own hoses connects and wiring

[@granturismo4000]

Absolutely love that video, will be doing this to my new XJ I’m planning on getting real soon here in UK. Would be handy for those extra miles. How many miles did you get to a tank fuel? Be interesting to know. :-) keep it up!

[@WAEMIDIV]

The best I ever did was a non-stop drive from Paducah, Kentucky all the way to Janesville, Wisconsin where I drove 449 miles on one tank. I was extremely impressed

[@granturismo4000]

@@WAEMIDIV that’s awesome! Definitely worth doing then. I’m actually getting the little donkey engine 2.5L AMC, so even more miles to be had. Very good reason to get it done. One I’ve found that I’ll be getting is a 1999 and has a few decent options too like LSD rear diff and AC (not many 2.5L with AC in UK. Lol). Thanks for the reply :-)

[@WAEMIDIV]

@@granturismo4000 Oh yes the 2.5L can get like 26 MPG (9+ L/100km) you'll be able to drive to every last corner of the UK before ya need to fill up

[@granturismo4000]

@@WAEMIDIV lol yeah our pokey little country you’ll end up in a traffic jam because some cones will be put out on a road so you can’t go anywhere. Lol. But yeah it’ll be nice to see what mileage I can get to a tank, gonna upgrade the injectors and the ignition system too for a smoother running motor. Lots of little things to help it a long.

[@johnykrystek5200]

i recently got a 93 zj with 85k on the dash, and a 20 gallon tank would kill me. having the actors few gallons is amazing, i’m curious to see how you’ll like it!

[@WAEMIDIV]

I do very much like it, I had a video in the works where I'd "review" it but that's been sort of pushed back because of more pressing issues the best I did was 449 miles from Paducah KY to Janesville WI and still had 2.4 gallons left. I love it

[@alexw8569]

I am very curious where you got the new J Bolts for the straps. I have been having a terrible time locating these. The ones on my XJ are toast and will need to be cut off. Thanks!

[@WAEMIDIV]

I don't remember deliberately ordering them, I think they came with the tank straps, but I'm not sure. I would order the tank straps and see if they include new J bolts, and if they don't, report back

[@Woahitsjurb]

Does it need to be a v8 or 4.0 donor tank? I’m not sure if they still came with the 4.0 in 97-98 just figured it would ask. And if they did still have both engine options I wonder if they’re the same sized tanks? Thanks!

[@WAEMIDIV]

Either engine has the same gas tank. I think that's pretty common in the automotive world, and is for the XJ too. A 2.5L will still have a 20 gallon tank, so you get bonus range They probly made the larger tank for the ZJ to get the V8 engines' range to about the same as the 4.0L, and if you got a 4.0L, you get some bonus gas storage

[@rpmillerthree]

I like what you are doing. Did I hear the first part of your video right, the 97 - 98 zj tank only works on the 97 to 01 XJ? I have a 96 and it would be nice that it could work. Let me know.

[@WAEMIDIV]

Yes, the ZJ tank uses a top mounted fuel pump and the 84-96 XJ has a metal tank with a side mounted pump. You might be able to do it, probably using a 96 ZJ tank, but I have no idea. As far as I know, it's never been done, and isn't documented anywhere, so you'd have to be a pioneer and see if it works yourself. I imagine it would involve splicing wires and some custom fabrication to some degree

[@michaelb2226]

@@WAEMIDIV I've had a 96 zj and it has the same tank as the 97-98.

[@carlt8188]

After watching this I will definitely NOT be doing this. However I really like your steering wheel cover. Where did you get it?

[@WAEMIDIV]

I have no idea, it came with my MJ when I bought it. Previous owner acquired it, and I transferred it to the XJ because my steering wheel is all peeling/ crumbling apart

[@mk3vr666]

I truly am a madman 😂

[@angerm088]

How is the Delphi pump doing? I found one source for a Bosch Pump but the pump is twice the price of a Delphi pump

[@WAEMIDIV]

I've had it for almost 25,000 miles already, no complaints here

[@angerm088]

@@WAEMIDIV That's good. I still don't like the mixed reviews on Delphi. There's one from 1AA Auto someone recommended and that seems like a top candidate. Is actually cheaper too to get including 2 day shipping. Guess Ill decide between TRQ/Delphi tomorrow pending some phone calls regarding a Bosch pump

[@xjjesus4391]

If I can afford it .. do u recommend the $1,700 one or no ?

[@WAEMIDIV]

Well I don't know, because personally I'd never spend almost 2 grand on a metal box. Even if I did have the money I wouldn't buy it because I think it's a complete rip off. That money could be spent on some good tires, some fancy new seats, or even gas itself. The 30 gallon tank also takes up a TON of room under the Jeep. There's no breathing room for the leaf springs, exhaust or axle, it'll make changing your differential fluid harder than it is now, and you will have spent the equivalent $$$ that could buy you an entire other XJ

[@bradlfsh]

So do you loose any ground clearance in the rear with this tank?

[@WAEMIDIV]

Not much if any, I never measured it exactly but the tank is still well within the departure angle from the bottom of the wheel to the rear bumper. The ZJ is pretty much exactly the same vehicle as the XJ

[@gosser66]

I agree with @WAEMID IV that you'll lose some clearance. He mentions that it's about an inch wider on each side, and that there alone doesn't account for nearly 3 more gallons. I'm very interested in this upgrade for my '98 XJ, and wondering about clearance and thinking about the ZJ skid plate.

[@stfisher65]

I have a 2001 XJ and my tank is significantly smaller than 20 gal. I can’t put more than 12 in mine.

[@WAEMIDIV]

I've heard rumors that some XJs could have a measly 13 gallon tank, but I don't have definitive proof on it. Handful of people out there like yourself have told me about this alleged very small gas tank

[@vintagestyle13]

Is the change to a plastic tank the only reason as to why it won't work in the early XJs? The 30g tank works in the earlier ones with the exception of having to use the 97-01 xj fuel pump.

[@WAEMIDIV]

I have no idea, I've never had the chance to inspect a pre-97 XJ in person. If you convert the fuel pump I bet it would work, because I'm pretty sure the frame rails/ mounts are the same

[@KaSwipeSter]

The fuel pump is also in a different location

[@vintagestyle13]

@@KaSwipeSter correct the early xjs had the pump in the front of the tank and the newer xjs/zjs the pump mounted from the top

[@KaSwipeSter]

@@vintagestyle13 yep have had to take out the fuel pump and tank on my xj twice now lol.

[@drgil65]

It’s been a year, how is the tank swap gone?

[@WAEMIDIV]

Excellent. No problems. Its actually saved me a time or two, where I fit 22 gallons into it at a fillup, which means I couldn't have driven that far with the stock tank. I have a range of 400 comfortable highway miles and I love it.

[@paveldvorak915]

How to drain the full tank other than you know, drive for 45 minutes?

[@WAEMIDIV]

You can disconnect the fuel line from the pump and let it run, otherwise the tank has anti-siphoning valves so you can't just stick a pipe down in it

[@paveldvorak915]

​@@WAEMIDIV I tried that, pump stops after 2 seconds, even when fuel line is disconnected, how to make it run permanently, is it checking pressure in common rails?

[@lance62]

Some XJ’s have 28 gallon fuel tanks. Mine has that optional fuel tank and my build sheet says, “8 additional gallons.”

[@WAEMIDIV]

Can you actually fit 28 gallons in it? Unless you're in a country that's not the US, I don't believe anything larger than the 20.2 gallon tank was offered. The base gas tank on the early XJs was 13 gallons. Given 13 is 7.2 gallons less than 20.2, it sounds like the build sheet generously rounds up to 8, claiming your additional 8 gallons over the base 13 gallon tank. They used a super small gas tank early on so that the curb weight of the vehicle would be less. The curb weight is what the vehicle weighs when completely filled with all fluids, and having a lower curb weight is a big selling point. They did the same thing with the long bed MJs - a 16 gallon tank was standard and a 23.5 gallon tank was optional. In ~1989, the base 16 gallon tank was dropped and they only had the 23.5 gallon tank.

[@lance62]

@@WAEMIDIV I don’t drive my XJ a lot but I don’t remember ever filling it up that high. With that being said, you make a very valid point; maybe “8 additional gallons” is the way the optional 20 gallon tank is described on Jeep Cherokee build sheets.

[@corbinfrazier9019]

wish i could do this on my '92...

[@WAEMIDIV]

Theoretically, one [might] be able to take a 93-96 ZJ tank and [potentially] put it in a 84-96 XJ. It just hasn't ever been documented, so someone would have to try it and see what happens- and what obstacles there are. A pioneer, if you will

[@John-oe6pp]

the battery is dead 😂. but for real tho its nice there's a cheap upgrade path for the gas tank.